NFA

NFA: Natural Fiber-reinforced Alginates

Introduction
Creating a composite material that is easily recyclable may sound straightforward, but it presents a complex challenge. Consequently, this thesis focuses on the development of a fiber composite material that is fully biodegradable. To achieve this aim, various components derived from algae are combined with fibers or fabrics to form a robust composite material.

Fiber-reinforced composites
Composite materials are of particular interest due to their capacity for a wide array of properties. The almost limitless possibilities for combining different constituents allow for the continual creation of new composites optimized for specific uses or suitable for diverse applications. In essence, composites comprise two or more discrete materials integrated in such a manner that the resulting composite manifests unique characteristics. However, this strength in combination also represents its most significant drawback; the material is often difficult to disassemble for recycling or reusability. This challenge inspired the idea of developing a composite material that is entirely biodegradable.

Institute
Dessau Department of Design

Student
Karl Richard Breitling

Support
Photography: Danida Schönherr
Model: Charlotte Gwendoline Quandt

Supervision
Prof. Dr. Manuel Kretzer
Prof. Nicolai Neubert

Project Date

2023

Category

Biomaterials

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Method
To accomplish this objective, I employ Material Driven Design (MDD), a methodology that situates the material at the core of the design process. Through a nuanced understanding of the material in question, the aim is to develop a holistic view of the material’s role within the design context. To unearth the latent potentials of the material, it is scrutinized from various vantage points: technical, experimental, historical, and contextual. Alongside the material development, corresponding product concepts are concurrently formulated. This dual-pronged approach facilitates an assessment of the material’s potential as well as guiding possible future directions for development.

Algae & Natural Fibers
Natural fibers have long held a position in the realm of composite applications. They not only exhibit performance potential comparable to synthetic fibers, but also offer additional benefits. For instance, natural fibers possess high vibration damping capacities, favorable fracture behavior, and their production can be both CO2-neutral and localized. Utilizing natural fibers enables the realization of a closed carbon cycle.

The fibers and fabric layers are cohesively bound using algae-derived components. Specifically, my experiments focused on sodium alginate, agar, and carrageenan, which are structural constituents found in the cell walls of brown and red algae. For the fabrication process, these components are dissolved in water and subsequently laminated with fibers or fabric in a mold. Upon drying, a robust composite material is formed.

Life cycle
The recyclability of raw materials is essential for a sustainable economy. To assess the environmental impact of a material, its life cycle provides a comprehensive overview. Currently, there is a nutrient imbalance between land and sea. While farmland is continually fertilized, these nutrients find their way into the sea via groundwater and rivers, leading to eutrophication and subsequent algal blooms that reduce oxygen levels. Controlled cultivation of algae could serve to filter these nutrients, binding them during processing and later reintroducing them into the nutrient cycle.

Fiber plants could be integrated into nature-based agricultural systems, creating an agro-ecosystem that both produces raw materials and contributes to biodiversity preservation. Biologist Robin Wall Kimmerer has described an experiment in which various cultivation methods were compared for their impact on plant growth. Interestingly, the lightly farmed field outperformed the one left to its own devices, suggesting that mindful agricultural practice can actually strengthen the ecosystem.

For the production of the Natural Fiber Algae (NFA) composite, manual processes have exclusively been used to date. Further research is needed to determine how these could be scaled up to an industrial level. Techniques such as laminating with an inner or outer mold and tensioning fabrics have proven effective. Once dried, the composites can be thermoplastically shaped using steam. Composites with shorter fibers can also be cast into molds. During the usage phase, technical properties like stability, tactile quality, and weight become critical. These attributes should be optimized in the design process. An added advantage of NFA is that it is fully biodegradable, eliminating the need for complex disassembly and recycling procedures.

Experiments
Each experiment is designed to address a specific question, ranging from broad inquiries to more detailed investigations. This approach has led to a matrix comprising over 100 samples that represent a wide range of experiments, involving combinations of different binders, fabrics, and fibers. In addition to these, various tests have been conducted on manufacturing processes, water resistance, and coloring. To establish a basis for comparison among the samples, they are subjected to a bending test to assess their structural stability. Alongside this mechanical evaluation, a visual assessment is carried out based on criteria such as surface quality, shape, strength/homogeneity, and the quality of fabrication.

Application concept
The design concept is formulated with the aim of showcasing the material’s inherent qualities. Based on the properties studied, two primary areas of application emerge. The intricate production process and higher cost of the natural fiber fabrics make them more suited for long-term indoor applications. Specifically, in environments with multiple sound sources such as offices or trade fairs, the material could positively impact room acoustics. On the other hand, for outdoor settings, the material’s biodegradability and ease of disposal serve as advantages, making it suitable for temporary structures or events.

In light of these material properties, the design was tailored for an office setting with a medium-term lifespan, with particular attention paid to acoustic attributes. The end product is a modular system composed of hexagonal and pentagonal elements. These can be assembled into either a panel or a dome using various connectors. The geometric configuration of the individual elements enhances both stability and sound diffusion, complemented by the material’s innate sound-absorbing characteristics.

Conclusion
The concept of a fully biodegradable composite has proven viable, marking the completion of a significant initial phase of iterations. The subsequent steps involve addressing challenges such as water and weather resistance. While natural fibers demonstrate aptitude for inclusion in composite materials, it is the cultivation and production processes that warrant more in-depth examination. In comparison to composites that employ a plastic matrix, the Natural Fiber Algae (NFA) material is not yet fully optimized for everyday applications. Therefore, substantial research remains to be conducted to refine NFA into a material that is practically useful.

Institute
Dessau Department of Design

Student
Karl Richard Breitling

Support
Photography: Danida Schönherr
Model: Charlotte Gwendoline Quandt

Supervision
Prof. Dr. Manuel Kretzer
Prof. Nicolai Neubert

Project Date

2023

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